Single or limited use device designs

ABSTRACT

The present disclosure is directed to an electrosurgical system. The electrosurgical system includes an electrosurgical generator configured to output electrosurgical energy and including a receptacle having at least one mechanical interface. The system also includes an electrosurgical instrument adapted to connect to the electrosurgical generator and configured to deliver energy to tissue. Further, a plug is provided to engage the receptacle to electrically couple the electrosurgical instrument to the electrosurgical generator. The plug includes a terminal electrically coupled to the electrosurgical instrument and a prong electrically coupled to the terminal that includes a recess defined therein and is configured to receive the at least one mechanical interface. When the plug is disengaged from the receptacle, the at least one mechanical interface cooperates with the recess to uncouple the prong from the terminal.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. application Ser. No.13/448,794, filed on Apr. 17, 2012, the entire contents of which arehereby incorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates to electrosurgical instruments used foropen and endoscopic surgical procedures for sealing or fusing tissue.More particularly, the present disclosure relates to systems and methodsfor limiting the number of times an electrosurgical instrument can beused.

2. Background of the Related Art

Energy-based tissue treatment is well known in the art. Various types ofenergy (e.g., electrical, ultrasonic, microwave, cryogenic, thermal,laser, etc.) are applied to tissue to achieve a desired result.Electrosurgical instruments have become widely used by surgeons inrecent years. By and large, most electrosurgical instruments arehand-held instruments, e.g., electrosurgical pencils, electrosurgicalforceps, endoscopic instruments such as monopolar forceps, bipolarforceps or a combination monopolar/bipolar forceps, ultrasonic handtools, microwave probes. Such electrosurgical instruments areelectrically coupled to an external electrosurgical generator.Alternatively, the electrosurgical instruments may be portable andinclude a battery powered electrosurgical generator.

Electrosurgical instruments have a limited number of uses before theyneed to be discarded. Reusing the electrosurgical instrument after ithas reached its limited number of uses may lead to complications duringelectrosurgery.

SUMMARY

This description may use the phrases “in an embodiment,” “inembodiments,” “in some embodiments,” or “in other embodiments,” whichmay each refer to one or more of the same or different embodiments inaccordance with the present disclosure. For the purposes of thisdescription, a phrase in the form “A/B” means A or B. For the purposesof the description, a phrase in the form “A and/or B” means “(A), (B),or (A and B)”. For the purposes of this description, a phrase in theform “at least one of A, B, or C” means “(A), (B), (C), (A and B), (Aand C), (B and C), or (A, B and C)”.

As shown in the drawings and described throughout the followingdescription, as is traditional when referring to relative positioning ona surgical instrument, the term “proximal” refers to the end of theapparatus that is closer to the user or generator and the term “distal”refers to the end of the apparatus that is farther away from the user orgenerator. The term “clinician” refers to any medical professional(i.e., doctor, surgeon, nurse, or the like) performing a medicalprocedure involving the use of aspects of the present disclosuredescribed herein.

Electromagnetic energy is generally classified by increasing energy ordecreasing wavelength into radio waves, microwaves, infrared, visiblelight, ultraviolet, X-rays and gamma-rays. As it is used in thisdescription, “microwave” generally refers to electromagnetic waves inthe frequency range of 300 megahertz (MHz) (3×10⁸ cycles/second) to 300gigahertz (GHz) (3×10¹¹ cycles/second).

The phrase “electrosurgical instrument” may refer to any instrumentconfigured to output electrosurgical energy such as electrosurgicalpencils, electrosurgical forceps, endoscopic instruments such asmonopolar forceps, bipolar forceps or a combination monopolar/bipolarforceps, ultrasonic hand tools, microwave probes.

In an aspect of the present disclosure, an electrosurgical system isprovided that includes an electrosurgical generator configured to outputelectrosurgical energy. The electrosurgical generator includes areceptacle having at least one mechanical interface. The system alsoincludes an electrosurgical instrument adapted to connect to theelectrosurgical generator and configured to deliver energy to tissue anda plug configured to engage the receptacle to electrically couple theelectrosurgical instrument to the electrosurgical generator. The plugincludes a terminal electrically coupled to the electrosurgicalinstrument and a prong electrically coupled to the terminal, the prongincludes a recess that is configured to receive the at least onemechanical interface. When the plug is disengaged from the receptacle,the at least one mechanical interface cooperates with the recess touncouple the prong from the terminal.

The prong includes a pair of contacts that are electrically coupled tothe terminal are biased in a spaced apart configuration. The plug mayalso include at least one tab, wherein upon disengagement of the plugfrom the receptacle the pair of contacts move proximally relative to theat least one tab thereby breaking the electrical coupling between theterminal and the prong.

In another aspect of the electrosurgical system, the plug may include achamber defined therein filled with a conductive medium that provideselectrical continuity between the terminal and the prong and wherein anda distal end of the prong seals the chamber. The conductive medium isreleased from the chamber thereby eliminating electrical continuitybetween the terminal and the prong and preventing further use of theelectrosurgical instrument.

In yet another aspect of the present disclosure, an electrosurgicalsystem is provided that includes an electrosurgical generator configuredto output electrosurgical energy. The electrosurgical generator includesa receptacle having at least one mechanical interface. The system alsoincludes an electrosurgical instrument adapted to connect to theelectrosurgical generator and configured to deliver energy to tissue anda plug configured to engage the receptacle to electrically couple theelectrosurgical instrument to the electrosurgical generator. The plugincludes a conduit electrically coupled to the electrosurgicalinstrument, a prong configured to be electrically coupled to thereceptacle, and a fuse electrically coupling the conduit to the prong.When the plug is disengaged from the receptacle, the at least onemechanical interface breaks the fuse to uncouple the prong from theconduit.

The fuse may be a wire and the mechanical interface may be a fuse cutterconfigured to cut the fuse. Alternatively, the mechanical interface maybe a ram configured to stress and/or flex the fuse to break the fuse.The fuse is configured to break after the ram stresses and/or flexes thefuse a predetermined number of times.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features, and advantages of the presentdisclosure will become more apparent in light of the following detaileddescription when taken in conjunction with the accompanying drawings inwhich:

FIGS. 1A and 1B are system block diagrams of electrosurgicalinstruments;

FIGS. 2A-2D are schematic diagrams of an electrosurgical plug andreceptacle according to an embodiment of the present disclosure;

FIGS. 3A and 3B are schematic diagrams of an electrosurgical plugaccording to another embodiment of the present disclosure;

FIGS. 4A-4D are a schematic diagrams of an electrosurgical plug andreceptacle according to another embodiment of the present disclosure;

FIG. 5 is a schematic diagram of an electrosurgical plug according toanother embodiment of the present disclosure;

FIG. 6 is a schematic diagram of an activation switch assembly accordingto another embodiment of the present disclosure; and

FIG. 7 is a schematic diagram of a lever assembly according to anotherembodiment of the present disclosure.

DETAILED DESCRIPTION

Particular embodiments of the present disclosure are describedhereinbelow with reference to the accompanying drawings; however, thedisclosed embodiments are merely examples of the disclosure and may beembodied in various forms. Well-known functions or constructions are notdescribed in detail to avoid obscuring the present disclosure inunnecessary detail. Therefore, specific structural and functionaldetails disclosed herein are not to be interpreted as limiting, butmerely as a basis for the claims and as a representative basis forteaching one skilled in the art to variously employ the presentdisclosure in virtually any appropriately detailed structure. Likereference numerals may refer to similar or identical elements throughoutthe description of the figures.

Turning to the figures, FIGS. 1A and 1B depict system block diagrams ofelectrosurgical instruments 10, 20 that have a single or limited usecapability. As shown in FIG. 1A, electrosurgical instrument 10 includesan electrosurgical interface or plug 100 that connects electrosurgicalinstrument 10 to an electrosurgical generator 500. Plug 100 is insertedinto a receptacle 502 of electrosurgical generator 500.

FIG. 1B depicts a system block diagram of an electrosurgical instrument20 which may be a portable system or provided as separate components.Electrosurgical instrument 20 includes an electrosurgical generator 22,which includes a power source, a control unit, sensors, memory, whichcooperate to generate an electrosurgical output to assembly 24 andmeasure responses therefrom. Assembly 24 may include a single electrode,multiple electrodes, one or more transducers, one or more antenna probesor a combination thereof. Generator 22 is electrically coupled to a fuse26 and an activation button 28. Activation button 28 may be a pushbutton switch, a toggle switch, lever, or any other mechanical devicethat may be used to activate electrosurgical instrument 20.

Turning to FIGS. 2A through 2D, a plug 200 according to an embodiment ofthe present disclosure is depicted. Plug 200 is electrically coupled toan electrosurgical instrument (not shown) via cable 230. Cable 230includes at least two conduits 231 and 232. Conduits 231 and 232, whichmay be a wire or any other transmission medium that conductselectricity, are electrically coupled, either directly or indirectly, toprongs 220 a and 220 b, respectively. Conduit 232 is coupled to terminal212 which is configured to receive the distal end of prong 220 b. Distalend of prong 220 b includes a pair of contacts 222 that are normallybiased to be spaced apart and electrically coupled to terminal 212.Contacts 222 may be biased apart by a spring or any other resilientmeans suitable for keeping contacts 222 spaced relative to one another.

During operation of an electrosurgical instrument that includes plug200, plug 200 engages receptacle 502 of an electrosurgical generator(see FIG. 1A). Prong 220 b includes a recess 221 b defined therein thatis configured to engage a corresponding protrusion 502 b in receptacle502. Protrusion 502 b can be any mechanical interface configured tomechanically engage recess 221 b. After plug 200 engages receptacle 502and upon activation of button 28, energy is supplied to electrosurgicalinstrument 10. In particular, conduit 232, terminal 212, contacts 222,prong 220 b are electrically coupled to terminal 502 b in receptacle 502while conduit 231 and prong 220 a are electrically coupled to terminal502 a thereby providing a path for energy. After the clinician finishesusing the electrosurgical instrument 10, plug 200 is removed fromreceptacle 502. When plug 200 is removed, protrusion 502 b cooperateswith recess 221 b to pull prong 220 b proximally. Pulling prong 220 bcauses contacts 222 to be pulled proximally. After contacts 222 passtabs 214, contacts 222 are fully spaced apart and rest on tabs 214thereby preventing any further electrical coupling between contacts 222and terminal 212.

FIGS. 3A and 3B depict a plug 300 according to another embodiment of thepresent disclosure. Plug 300 includes a conduit 330 that is electricallycoupled to an electrosurgical instrument 10. Conduit 330 includes aconduit 332 that is electrically coupled to terminal 312 in chamber 310.Chamber 310 is filled with a conductive gas 314 such as argon, carbondioxide, helium, neon, hydrogen peroxide, etc. Gas 314 electricallycouples terminal 312 to distal end 322 of prong 320. Distal end 322seals aperture 316 defined in chamber 310 preventing gas 314 fromescaping therefrom. Recess 321 of prong 320 engages protrusion 502 b inreceptacle 502 to pull prong 320 proximally when plug 300 is disengagedfrom receptacle 502. Disengaging plug 300 causes distal end 322 todisengage aperture 316 allowing gas 314 to escape from chamber 310 asshown in FIG. 3B. Without the conductive gas 314 being disposed inchamber 310, electrosurgical energy is prevented from being transmittedtherethrough. Thus, plug 300 is prevented from being used in asubsequent procedure.

FIGS. 4A to 4D depict a plug 400 and receptacle 450 according to anotherembodiment of the present disclosure. Plug 400 includes a prong 420 thatis electrically coupled to an electrosurgical instrument via a conduit432 and a fuse 434. Fuse 434 may be a wire or any other conductivematerial. Receptacle 450 includes a mechanical interface or fuse cutter440 having a sharp edge 442 (as shown in FIG. 4D). When plug 400 isinserted into receptacle 450, fuse 434 slides over the distal end 441 offuse cutter 440. After plug 400 is removed, sharp edge 442 cuts fuse 434severing the electrical connection between prong 420 and conduit 432 asshown in FIG. 4C thereby preventing electrosurgical instrument 10 fromfurther use.

FIG. 5 depicts a plug 500 and receptacle 550 according to anotherembodiment of the present disclosure. As shown in FIG. 5, plug 500includes a prong 520 that is electrically coupled to conduit 532 viafuse 534. Receptacle 550 includes a flange or ram 540 having a flatsurface on a distal end thereof. When plug 500 is inserted intoreceptacle 550, ram 540 makes contact with fuse 534 and causes fuse 534to be flexed and/or stressed. Fuse 534 is designed to break after ram540 engages fuse 534 one or a predetermined number of times.

FIGS. 6 and 7 depict different embodiments for use with electrosurgicalinstrument 20 of FIG. 1B. The embodiments shown in FIGS. 6 and 7 can beused to limit use of electrosurgical instrument 20 for a predeterminednumber of times. For instance as shown in FIG. 6, electrosurgicalinstrument 20 may include an activation button 610 having ram 612 and asurface 614. When activation button 610 is pressed, surface 614 engagesa push button switch 624 thus activating electrosurgical instrument 20.Surface 614 may be a conductive surface and push button switch 624 maybe replaced by a pair of non-contacting electrodes (not shown) such thatwhen activation button 610 is depressed, second surface 614 contacts thepair of electrodes to activate the electrosurgical instrument. Whileactivation button 610 is depressed, ram 612 causes fuse 622 to flexand/or stress. Fuse 622 may be designed to break after ram 612 engagesfuse 622 a predetermined number of times.

As shown in FIG. 7, an electrosurgical instrument according to anotherembodiment of the present disclosure may include a lever 710 having aflange or ram 712 configured to activate the electrosurgical instrument20. When lever 710 is depressed, ram 712 stresses and/or flexes fuse 722to weaken fuse 722. Fuse 722 may be designed to break after flange 712rams fuse 722 a predetermined number of times.

Although the above described embodiments disclose a recess in the prongof a plug and a protrusion in the receptacle of the electrosurgicalgenerator, in alternative embodiments, the receptacle may include arecess, while the prong includes the protrusion.

While several embodiments of the disclosure have been shown in thedrawings and/or discussed herein, it is not intended that the disclosurebe limited thereto, as it is intended that the disclosure be as broad inscope as the art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. The claims canencompass embodiments in hardware, software, or a combination thereof.Those skilled in the art will envision other modifications within thescope and spirit of the claims appended hereto.

1-11. (canceled)
 12. A plug configured to engage a receptacle of anelectrosurgical generator, the plug comprising: a terminal adapted to beelectrically coupled to an electrosurgical instrument; and a prongelectrically coupled to the terminal, the prong including a recessdefined therein and configured to receive at least one mechanicalinterface of the receptacle, wherein, when the plug is disengaged from areceptacle of the electrosurgical generator, the recess cooperates withthe at least one mechanical interface to uncouple the prong from theterminal.
 13. The plug according to claim 12, wherein the prong includesa pair of contacts that are electrically coupled to the terminal. 14.The plug according to claim 13, wherein the prongs are biased in aspaced apart configuration.
 15. The plug according to claim 14, furthercomprising at least one tab defined therein wherein, upon disengagementof the plug from a receptacle, the pair of contacts move proximallyrelative to the at least one tab thereby breaking the electricalcoupling between the terminal and the prong.
 16. The plug according toclaim 12, further comprising a chamber defined therein filled with aconductive medium that provides electrical continuity between theterminal and the prong and wherein a distal end of the prong seals thechamber.
 17. The plug according to claim 16, wherein, upon disengagementof the plug from a receptacle, the conductive medium is released fromthe chamber thereby eliminating electrical continuity between theterminal and the prong and preventing further use of the electrosurgicalinstrument.
 18. The electrosurgical system according to claim 16,wherein the conductive medium is argon.
 19. A plug configured to engagea receptacle of an electrosurgical generator, the plug comprising: aconduit adapted to be electrically coupled to an electrosurgicalinstrument; a prong configured to be electrically coupled to areceptacle; and a fuse electrically coupling the conduit to the prong,wherein, when the plug is disengaged from a receptacle a predeterminednumber of times, the fuse breaks thereby uncoupling the prong from theconduit.
 20. The electrosurgical system according to claim 19, whereinthe fuse is a wire.